Spacer using spacing bags and method for loading tube packs on railcars

ABSTRACT

A method and apparatus for loading tube bundles on a railcar includes placing the tube bundles lengthwise on the car and stacked above the car to form packs. These packs are spaced longitudinally one from another on the car. Spacing bags are placed within the longitudinally extending spaces. Plates are displaced one from another by the spacing bags to push against the ends of the packs.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser.No. 61/076,558, filed Jun. 27, 2008, entitled “SPACER USING SPACING BAGSAND METHOD FOR LOADING TUBE PACKS ON RAILCARS”, the contents of whichare incorporated by reference herein.

FIELD OF THE INVENTION

The field of the present invention is related to systems and methods forloading railcars.

BACKGROUND OF THE INVENTION

The rail industry has a great deal of experience in the handlingmaterials on railcars. Particular requirements have been established forstacking materials on flat cars including dunnage, blocking and specificstrapping requirements.

With bundled and elongate products such as tubing, wood beams are laidlaterally across the car as dunnage to support the bundles as shown inFIG. 1. The tubes are in bundles and extend longitudinally on therailcar. Short stakes, blocking and strapping them retains the load inplace. FIG. 2 illustrates one such recommended stacking.

In spite of these carefully defined methods for retaining tube bundles,the natural vibration of the railcar can result in individual tubes inthe bundle slowly working longitudinally outwardly from the bundle,telescoping outward. If left unattended, the individual tubes can extendinto harms way or come into contact with adjacent tube bundles orbulkheads. This can make the bundles difficult to unload and causedamage to the tubing. Naturally, bulkheads can be placed against theends of the tubing or the tubing against barriers. However, such tightassemblies create their own problems in terms of loading, unloading anddamage from motion of the tubes relative to other tubes, the bulkheadsand barriers.

Currently, a wooden spacing block is used to separate one bundle oftubes on a railcar from another bundle. The spacing block is constructedof two wooden plates with wood blocks between the two wooden plates. Inorder to use the wood blocks the distance between the two plates ismeasured and the wood blocks are inserted and hammered between the twoplates. In many instances a significant amount of time and effort tonail down the wooden blocks. The spacing block system is described ingreater detail are spent with regards to the methods of U.S. Pat. No.7,381,021 entitled “Method For Loading Tube Bundles on Railcars”.

SUMMARY

The present invention is directed to a method and apparatus for securingtube bundles on a railcar. The tube bundles are placed lengthwise on thebed of the railcar and stacked conventionally above the bed to formpacks of multiple tube bundles. Spaces are left between adjacent packsof tube bundles. An assembly using spacing, air filled bags and platesdisplaced from one another by the bags can be positioned in the spacebetween adjacent ends of tube bundles. The spacing air filled bags arepositioned on the bed between longitudinally adjacent packs and in oneembodiment can be fixed to the bed of the railcar. Accordingly, theassembly can provide an improved method and apparatus for loading tubebundles on a railcar. Other and further objects and advantages willappear hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a railcar with tube bundles stacked thereon asin the prior art.

FIG. 2 is an end view of the prior art stacked tube bundles of FIG. 1.

FIG. 3 is a perspective view of one embodiment of the apparatus of thisinvention using spacing bags.

FIG. 4 is a side view of a railcar with tube bundles and one embodimentof the spacer apparatus of this invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A railcar, generally designated 10, includes a bed 12 and bulkheads 14,16. The bulkheads 14, 16 are shown to be at either end of the bed 12.The railcar also includes standard railroad trucks, couplings andequipment (not shown).

Tube bundles 18 are shown placed on the bed 12 in accordance withstandard practice. One such example of approved tube bundle stacking isillustrated in FIG. 2 which shows the packing of various sizes of tubebundles 18. Typically the tube bundles 18 are placed on the bed 12 byforklifts, but can be placed using other suitable means. The tubebundles 18 are arranged with spaces extending longitudinallytherebetween. Conveniently, the packs of tube bundles 18 are also spacedaway from the bulkheads 14,16. With this spacing, the bundles 18 can beeasily and quickly loaded and unloaded from the bed 12 of the railcar10. Strapping 20 can be used tie each of packs of tube bundles 18 to thebed 12 of the railcar 10. Stakes 34 can be used to prevent rolling ofthe packs of tube bundles 18.

In a first embodiment of the present invention as shown in FIGS. 3 and4, a spacer 80 can occupy the space between the packs of tube bundles.The spacer 80 can be constructed such that it cushions, protects andprevents damage to the packs of tube bundles 18, bed 12, bulkheads 14and 16 and areas surrounding railcar as it travels. Another function ofthe spacer 80 can be to prevent telescoping of any one or plurality oftubes in the pack of tube bundles 18. Spacer 80 can prevent loose tubesin the tube bundles 18 from interfering with adjacent structure orelements and prevent difficulties in offloading tube bundles. The spacer80 may be configured to fit within the space between tube bundles 18vertically in the railcar 10 between longitudinally adjacent packs oftube bundles 18 and between the bulkheads 14, 16 and the most adjacentpacks of tube bundles 18.

In the first embodiment, the spacer 80 can includes a plurality ofplates 24 and 26, and at least one spacing bag 48. The plates 24 and 26can be constructed of a plurality of separate plates that are rigid. Forexample plates 24 and 26 can be made from wood, metal, pressed wood,plastic or the like. Spacing bag 48 can be an inflatable bag createdfrom a flexible material such as for example plastics, polymers, clothor polyurethane. In other embodiments, the spacing bag 48 can beconstructed out of a dual layer material, where the inner layer acts asthe bladder receiving the air and the outer layer is constructed from amore resilient material to prevent puncturing. The spacing bag 48 canhave a length and a width dimension and have an inseam running along theperimeter of the spacing bag 48. The spacing bag 48 is not limited tothe shape as shown and can be rectangular, circular, rounded or shapedto accommodate particular objects.

The spacing bag 48 and the plates 24 and 26 are initially adjusted to bethinner than the space into which the spacer 80 is placed, specificallyto facilitate placement of the spacer 80 on the bed 12 between packs oftube bundles 18 and/or bulkheads 14, 16. The spacing bag 48 may beemployed to define the displacement of the rigid plates 24 and 26. Adeflated spacing bag 48 or a partially inflated spacing bag 48 can beinserted between the plates 24 and 26. Inflating or filling the spacingbag 48 can displace the two plates 24 and 26 away from each other andagainst the wall of the tube packs. The spacing bag 48 can be inflatedusing a gas or a fluid, such as but not limited to, compressed air,helium, water or the like. In the first embodiment the spacing bag 48 isinflated with air until it exerts pressure on the pates 24 and 26 andthereby the spacer 80 exerts pressure on packs of tubes 18. The pressureinside the spacing bag can be about 7 to 12 P.S.I. In an alternativeembodiment the spacing bag can be inflated to about 10 P.S.I.

In a second embodiment the spacer 80 can include plates 24 and 26covered on at least one side with a cushioning material 32. To ensurethat the ends of the tubes coming into contact with the spacer 80 willnot be injured by vibrations against the plates 24 and 26, a cushioningmaterial 32 can be placed on the surfaces of the plates 24 and 26. Thesecushions may be applied by any means including gluing or stapling orplacement without begin affixed to the plates. The cushioning material32 can be made of a plurality of material, for example, foam, plastic,carpet or burlap. In an alternative embodiment, the cushioning material32 can be on both sides of the plates 24 and 26, to provide a cushionfor the spacing bag 48.

In a third embodiment shown in FIG. 4, strapping 30 can extend over thespacing bag 48 which lies along the peripheral edge of the plates 24, 26and set in adjacent to the bed 12 of the railcar 10.

The overall process of loading tube bundles 18 includes placing the tubebundles on a flat car 10. Stakes 34 on the edges of the flat car 10 andblocks 36 against the bundles 18 insure the bundles 18 do not roll fromthe car 10. Wood beams 38 are placed between bundles as dunnage.Strapping 20 can tie the load down. The spacer 80 can be positioned onthe bed 12 of the railcar 10 in the longitudinal space between bundleends. The entire load may be covered by using covering 50. The covering50 can be a flexible material, such as but not limited to, tarp,plastic, polymers, polyurethane, capable of deflecting debris duringtransportation of the rail car 10. The covering 50 can protect thespacer 80 and the spacing bag 48 from being struck by various objectsduring transport.

In a fourth embodiment, plates 24 and 26 can be placed along the sidesof two adjacently spaced tube bundles 18. The rigid plates 24 and 26 canbe covered on both side with a cushioning material 32. Next a deflatedspacing bag 48 can be placed between the two plates 24 and 26 and placednear the railcar bed 12. The spacing bag 48 can include a value 52 toallow a device, such as a pump or compressor, to insert gases or fluidinto the spacing bag 48. The pump can insert air into a spacing bag 48to about 8 to 12 P.S.I., preferably 10 P.S.I. The inflated spacing bag48 can exert pressure against plates 24 and 26. If needed, spacing bag48 can be further inflated to exert greater pressure against rigidplates 24 and 26. In one embodiment the spacing bag 48 can exertsufficient pressure against the tubing bundles so that when they aretied with strapping 20 this creates a single unit out of a plurality oftubing bundles 18. In an alternative embodiment a second spacing bag 48can be placed on top of the first spacing bag if the rigid plates 24 and26 height allow space for the second spacing bag 48. The second spacingbag 48 can be inflated using a valve 52. In another embodiment, therigid plates 24 and 26 can be coupled to the railcar for furthersecurity by nails, screws or the like (not shown).

The inflation of a spacing bag 48 can take up to 3 minutes depending onthe pump used, preferably less than 2 minutes. To disassemble the spacer80 created by the inflation spacing bag 48 the valve can be opened torelease the air out of the spacing bag 48. Deflating the spacing bag 48reduces the pressure against plates 24 and 26 allowing their removal andaccess to the pack of tube bundles 18.

According to a fifth embodiment of the current invention, each componentof the spacer 80 can be assembled away from the railcar 10. The spacer80 can have two plates 24 and 26, coupled to one another using aflexible means, such as but not limited to, a cloth, plastic or tarpwhich would wrap around or over the plates (not shown). The flexiblemeans can be attached to each of the plates at the perimeter of theplate. At least one spacing bag 48 can be inserted between plates 24 and26 and inside the perimeter created by the flexible means. A valve toallow the inflation of the spacing bags 48 can be located outside theflexible means. The plates 24 and 26 can be covered on both sides withthe cushioning material 32. In an alternative embodiment the cushioningmaterial can be used as the flexible means to connect the plates 24 and26 (not shown). For example, plastic could be nailed to the bottom outersurface of each plate and extend over the top to encompass the bags 48.

The spacer 80 can be partially inflated prior to its placement on therailcar bed 12. After the placement of the packs of bundles of tubes 18,the spacer 80 of the fifth embodiment can be inserted into the spacebetween the bundles of tubes 18. A pump or compressor can be connectedto the valve and the spacing bag 48 or plurality of spacing bags can beinflated to the appropriate pressure. During the inflation the flexiblemeans can stretch or be sufficiently loose to allow the plates 24 and 26to exert pressure on the bundles of tubes 18 when fully inflated. Usingthis method can reduce assembly time.

In a sixth embodiment, the spacer 80 can have spacing bags 48 that areaffixed to the plates 24 and 26. The spacer 80 with partially deflatedspacing bags 48 can be inserted into the space between two sets of packsof bundles of tubes 48. Next the spacing bags 18 can be inflated toexert outward pressure on the packs of bundles of tubes 48. Inalternative embodiments multiple spacing bags can be used in one spacer80.

Accordingly, an improved system for loading tube bundles on a railcarhas been disclosed. While embodiments and applications of this inventionhave been shown and described, it would be apparent to those skilled inthe art that many more modifications are possible without departing fromthe inventive concepts herein. The invention, therefore is not to berestricted except in the spirit of the appended claims.

1. A method for loading tube bundles on a railcar having a bed andbulkheads, comprising: placing tube bundles lengthwise on the bed andstacked above the bed to form packs of multiple tube bundles and whenall packs are loaded on the railcar to leave a longitudinal gap betweenadjacent packs, or between one of the bulkheads and the most adjacentpack; and, inflating at least one first spacing bag between adjacentpacks to push against the respective adjacent ends of the packs toprovide a spacer in the longitudinal gap.
 2. The method of claim 1further comprising placing plates between the spacing bag and theadjacent ends of the packs.
 3. The method of claim 2 further comprisingplacing resilient material on at least one side of the plates.
 4. Themethod of claim 1 further comprising at least partially deflating thespacing bag prior to insertion between adjacent packs, and subsequentlyinflating the spacing bag when placed between adjacent packs.
 5. Themethod of claim 4 wherein the spacing bag inflated to about 7 to 12 PSI.6. The method of claim 4 wherein the spacing bag is inflated to about 10PSI.
 7. The method of claim 3 wherein the resilient material comprises acushioning material.
 8. The method of claim 7 wherein the cushioningmaterial is applied to both sides of the plates.
 9. The method of claim1 further comprising securing strapping to the bed of the rail car andextending the strapping over the top of the spacing bag.
 10. The methodof claim 9 wherein the strapping extends over plates positioned betweenthe spacing bag and adjacent ends of the packs.
 11. The method of claim1 further comprising securing a covering to the rail bed and extendingthe covering over the entire load of bundles and the spacing bag. 12.The method of claim 9 wherein the spacing bag is inflated to exertsufficient pressure against the ends of the tube bundles so that asemi-rigid unit is created of two bundles and the spacing bag when thestrapping is secured.
 13. The method of claim 1 wherein the secondspacing bag is placed above the first spacing bag and inflated to pushagainst the respective ends of the tube packs.
 14. The method of claim 1wherein the plates are rigid plates and are coupled to the rail car bed.15. The method of claim 1 wherein at least one plate is coupled to thespacing bag.
 16. The method of claim 15 wherein a plate is secured toboth sides of the spacer bag.
 17. The method of claim 16 wherein theplates are secured by a flexible material.
 18. The method of claim 16wherein the spacing bag and the plates comprise a unit which is insertedbetween adjacent ends of the tube bundles; and inflating the spacing bagto push the plates against respective ends of the tube bundles.
 19. Themethod of claim 17 wherein the spacing bag is inflated to stretch theflexible means to allow the plates to exert pressure against the tubebundles when the spacing bag is inflated.
 20. A method of loading tubebundles on a rail car having a bed and bulkheads, comprising: placingtube bundles lengthwise on the bed and stacked above the bed to formpacks of multiple tube bundles and when all the bundles are loaded onthe rail car to leave a longitudinal gap between the adjacent packs, orbetween one of the bulkheads and the most adjacent packs; placing platesbetween the adjacent ends of the packs; and inflating at least one firstspacing bag between the adjacent packs to push the plates against therespective ends of the packs to provide a spacer in the longitudinalgap.
 21. A method to loading two bundles on a rail car having a bed andbulkheads, comprising: placing tube bundles lengthwise on the bed andstacked above the bed to form packs on multiple tube bundles and whenall the packs are loaded on the rail car to leave a longitudinal gapbetween the adjacent packs, or between one of the bulkheads and mostadjacent pack; at least partially deflating a spacing bag prior toinsertion between adjacent packs, and subsequently inflating the spacingbag when placed between adjacent packs to push against the respectiveends of the adjacent packs to provide a spacer in the longitudinal gap.22. A method of loading bundles on a rail car having a bed andbulkheads, comprising: placing tube bundles lengthwise on the bed andstacked above the bed to form packs of multiple tube bundles and whenall the packs are loaded on the rail car to leave a longitudinal gapbetween the adjacent packs, or between one of the bulkheads and the mostadjacent pack; securing strapping to the bed of the rail car andextending the strapping over the top of a spacing bag; and inflating thespacing bag to exert sufficient pressure against the ends of the tubebundles so that a semi-rigid unit is created of adjacent bundles and thespacing bag when the strapping is secured.
 23. A method for loading twobundles on a rail car having a bed and bulkheads, comprising: placingtube bundles lengthwise on the bed and stacked above the bed to formpacks and multiple tube bundles and when all the packs are loaded on therail car to leave a longitudinal gap between adjacent packs, or betweenthe bulkheads and the most adjacent pack; and placing a first and asecond spacing bag between adjacent packs and inflating the spacing bagsto push against respective ends of the tube packs.
 24. A method ofloading two bundles on a rail car having a bed and bulkheads,comprising: placing tube bundles lengthwise on the bed and stacked abovethe bed to form packs of multiple tube bundles and when all the packsare loaded on the rail car to leave a longitudinal gap between adjacentpacks, or between one of the bulkheads in the most adjacent packproviding a spacing bag and at least one plate; inserting a spacing bagand a plate between adjacent ends of the tube bundles; and inflating thespacing bag to push the plate against the end of a tube bundle.